Printed circuit board assembly with improved terminals and method for manufacturing the same

Abstract

Printed circuit board (PCB) unit (90), comprising: a PCB (12) having a first surface (12a) and a second surface (12b); a first electrical terminal (30, 50) mounted on the PCB (12), the first electrical terminal (30, 50) comprising a body having a first end (30a, 50a) and a second end (30b, 50b), a mounting portion (36, 52) extending outwardly from the first end (30a, 50a) and adapted to be inserted into an opening (12c) formed in the PCB (12), lugs (34) formed adjacent to the mounting portion (36, 52) and a first insertion tab (38) extending outwardly from the body at the first end (30a, 50a) thereof, wherein the lugs (34) of the first electrical terminal (30, 50) are disposed between the first insertion tab (38) and the mounting portion (36, 52) of the first electrical terminal (30, 50); and wherein the lugs (34) of the first electrical terminal (30, 50) are configured to engage the second surface (12b) of the PCB (12); and a second electrical terminal (40,60) mounted adjacent to the first electrical terminal (30,50) on the PCB (12), the second electrical terminal (40,60) having a body with a first end (30a,50a) and a second end (40b), a mounting portion (36, 52) extending outwardly from the first end (30a, 50a) and adapted to be inserted into an opening (12c) formed in the PCB (12), lugs (44) formed adjacent to the mounting portion (36, 52), and a second insertion tab (42) extending outwardly from the body at the first end (30a, 50a) thereof, the lugs (44) of the second electrical terminal (40, 60) being disposed on a first surface (42a) of the second insertion tab (42) and being adapted to engage the second surface (12b) of the PCB (12); wherein the first insertion lug (38) and the second insertion lug (42) are axially spaced from each other so that the first electrical terminal (30, 50) and the second electrical terminal (40, 60) do not touch each other.

Description

BACKGROUND

[0001] This invention generally relates to printed circuit board (PCB) assemblies having a PCB and electrical terminals attached thereto. More particularly, this invention relates to an improved electrical terminal for such a PCB assemblies that facilitates more efficient and effective placement of a plurality of the improved electrical terminals on the PCB. The invention further relates to a method of manufacturing a printed circuit board (PCB) assemblies.

[0002] Such PCB units can be found in a variety of applications, such as power distribution systems or junction boxes used to manage power distribution in automobiles. Junction boxes typically have enclosures and a printed circuit board with electrical terminals, fuses, relays, circuit breakers, and other electrical devices mounted thereon. Electrical devices, such as connectors and wiring harnesses, can be connected to the terminals through the enclosures.

[0003] The electrical terminals may include terminal blade contact portions, forked terminal receptacles, and / or portions of any other desired configuration and combinations thereof extending from one or both surfaces of the PCB.

[0004] The terminals may have insertion tabs extending substantially transversely from the terminal. The insertion tabs provide an engagement surface for an insertion tool to engage the terminal and push it through an opening in the PCB, thereby mounting the terminal to the PCB. The insertion tabs are typically flat and located in the same plane as a body of the terminal.

[0005] A plurality of terminals may be mounted in a row on the PCB such that the terminals are substantially coplanar. When adjacent terminals are mounted on the PCB in this manner, the insertion tabs may also be coplanar. Adjacent terminals are typically mounted with a minimum spacing between terminals, for example, to ensure that adjacent electronically conductive terminals do not touch each other and / or to provide clearance for a wall of a package that may be mounted around each terminal. A minimum center-to-center spacing between adjacent terminals is thus determined by the size of the insertion tabs, which extend substantially transversely of and in the same plane as the body of the terminal.

[0006] However, end users of conventional junction boxes may desire a reduced package size for the junction box, which would require smaller PCB units within the smaller junction box. It is therefore desirable to provide a terminal layout that allows adjacent terminals to be mounted closer together, thereby reducing the center-to-center distance between adjacent terminals and potentially reducing the PCB unit size and the junction box package size.

[0007] An electrical connector assembly is known from US 7 963 776 B1. It comprises a printed circuit board with vias extending at least partially through the printed circuit board along via axes, wherein the vias are unplated vias. The printed circuit board has conductive traces and mounting pads electrically connected to corresponding conductive traces, wherein the mounting pads are exposed within corresponding vias. The vias have a stepped diameter along the via axis with a narrowed region near the mounting pad. The electrical connector assembly further comprises an electrical connector mounted on the printed circuit board, wherein the electrical connector has a housing and signal terminals held by the housing.The signal terminals have mounting contacts configured to be received in corresponding vias of the printed circuit board, with the mounting contacts engaging the corresponding mounting pads within the constricted area of ​​the via.

[0008] US 4,030,792 A discloses a device for connecting blade contacts to external circuits. Tuning-fork-shaped socket contacts are press-fitted into a printed circuit board, and an insulating housing is placed over the top of the contacts. The structure of the insulating housing provides a closed entry for blade contacts to protect the ends of the tuning-fork contacts from damage during mating. SUMMARY OF THE INVENTION

[0009] This invention relates to an improved PCB assembly that allows adjacent terminals to be mounted closer together on the PCB than is possible with known PCB assemblies.

[0010] An embodiment of the PCB assembly according to the invention comprises a PCB having a first surface and a second surface, and first and second electrical terminals mounted on the PCB. The first electrical terminal includes a body having a first end and a second end, a mounting portion extending outwardly from the first end and configured for insertion into an opening formed in the PCB, bosses formed adjacent to the mounting portion, and a first insertion tab extending outwardly from the body at the first end thereof. The bosses of the first electrical terminal are disposed between the first insertion tab and the mounting portion of the first electrical terminal. The bosses of the first electrical terminal are configured to engage the second surface of the PCB.The second electrical terminal is mounted adjacent to the first electrical terminal and includes a body having a first end and a second end, a mounting portion extending outwardly from the first end and configured for insertion into an opening formed in the PCB, lugs formed adjacent to the mounting portion, and a second insertion tab extending outwardly from the body at the first end thereof. The lugs of the second electrical terminal are disposed on a first surface of the second insertion tab and configured to engage the second surface of the PCB. The first insertion tab and the second insertion tab are axially spaced apart from each other such that the first electrical terminal and the second electrical terminal do not contact each other.

[0011] Various advantages of the invention will become apparent to those skilled in the art from the following detailed description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a cross-sectional side view of a portion of a known PCB assembly. Fig. 2 is a cross-sectional side view of a portion of an improved PCB assembly according to the invention, shown after a first step of a first embodiment of a method of assembling the improved PCB assembly. Fig. 3 is a cross-sectional side view of a portion of the Fig. 2, shown after a second step of the first embodiment of a method for assembling the improved PCB unit. Fig. 4 is a perspective view of a first electrical terminal of a first embodiment. Fig. 5 is a sectional side view of a second electrical terminal of a first embodiment. Fig. 6 is a sectional side view of a first electrical terminal of a second embodiment. Fig. 7 is a sectional side view of a second electrical terminal of a second embodiment. Fig. Fig. 8 is a sectional side view of a fifth embodiment of a non-inventive Fig. 2 and Fig. 3 shown electrical connection. Fig. 9 is a sectional side view of a sixth embodiment of a Fig. 2 and Fig. 3 shown electrical connection. DETAILED DESCRIPTION

[0012] The present invention will now be described with reference to specific embodiments of the invention. This invention may, however, be embodied in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0013] In Fig. 1 shows a section of a known PCB unit 10. The Fig. The PCB unit 10 shown in Figure 1 comprises a PCB 12 having a first main surface 12a (upper surface in Fig. 1) and a second main surface 12b (lower surface in Fig. 1) and a plurality of tuning-fork-like electrical terminals 14. The terminals 14 are inserted into terminal openings 12c formed through the PCB 12.

[0014] As in Fig. 1, each terminal 14 includes a body 16 having a first end 16a and a second end 16b. The first end 16a has a mounting pin 18 extending therefrom and forms lugs 20 adjacent the mounting pin 18. The mounting pin 18 is configured for insertion and mounting in the openings 12c of the PCB 12, and the lugs 20 are configured to engage the second major surface 12b of the PCB 12.

[0015] The second end 16b is configured as a tuning fork-like terminal socket and includes two substantially parallel rods 22 defining a slot 23 formed therebetween for receiving an electrical engaging member, such as a terminal blade contact member of another electrical device (not shown). Interlocking projections or elements 22a extend inwardly from the rods 22 (into the slot 23) and are configured to provide an improved friction fit of the terminal blade contact member or other electrical engaging member received in the slot 23.

[0016] Insertion tabs 24 extend outwardly from the connector body 16 between the lugs 20 and the tuning-fork-like connector socket 16b and are spaced a distance from the lugs 20. In a known manner, the insertion tabs 24 extend substantially transversely from and in the same plane as the connector body 16.

[0017] As in Fig. 1, the terminals 14 are identical, so that when mounted on the PCB 12, the insertion tabs 24 of adjacent terminals 14 are coplanar and linearly aligned along a line L1. Accordingly, a minimum center-to-center distance CL1 between adjacent terminals 14 is limited by the proximity of adjacent insertion tabs 24 to one another. For example, in the Fig. In the embodiment illustrated in Figure 1, the terminals 14 have a width W1, measured from the outer surfaces of the insertion tabs 24, of approximately 5.0 mm to approximately 5.2 mm. When assembled in a known manner as shown, the centerlines of adjacent terminals 14 are spaced apart by a distance CL1 of between approximately 6.5 mm and approximately 6.7 mm.

[0018] In Fig. 4 to 9 illustrate alternative embodiments of electrical connections, which are described in detail below and are suitable for use in a Fig. 2 and Fig. 3 are suitable for the improved PCB unit 90 according to the invention.

[0019] In Fig. 4, a first embodiment of an electrical terminal is shown at 30. The electrical terminal 30 includes a mounting portion or first end 30a and a first embodiment of a second end 30b. The first end 30a is configured as a blade contact portion. The illustrated blade contact portion 30a has a width W2 of between approximately 2.4 mm and approximately 2.6 mm.

[0020] The second end 30b is configured as a tuning fork-type terminal socket, substantially similar to the tuning fork-type terminal socket 16b described above. The tuning fork-type terminal socket 30 includes two substantially parallel bars 32 defining a slot 33 formed therebetween for receiving an electrical engaging member, such as a terminal blade contact member of another electrical device (not shown). Interlocking projections or elements 32a extend inwardly from the bars 32 (into the slot 33) and are configured to provide an improved friction fit of the terminal blade contact member or other electrical engaging member received in the slot 33.

[0021] Lugs 34 are formed at an interface of the blade contact portion 30a and the tuning fork-type terminal socket 30b. The blade contact portion 30a is configured for insertion through the openings 12c of the PCB 12, and the lugs 34 are configured for engagement with the second major surface 12b of the PCB 12, as shown in Fig. 3 and is described in detail below.

[0022] A mounting portion 36 is formed at a proximal end of the blade contact part 30a adjacent to the second end 30b. As best shown in Fig. As can be seen in Figure 3, the mounting portion 36 has a width W3 that is greater than the width W2 of the blade contact part 30a. The illustrated mounting portion 36 has a width W3 between approximately 3.4 mm and approximately 3.6 mm. The mounting portion 36 is designed to be inserted and mounted in the openings 12c of the PCB 12.

[0023] Insertion tabs 38 extend outwardly from the tuning fork-like terminal socket 30 between the lugs 34 and the rods 32 and have a first surface 38a and a second or tool engagement surface 38b. The insertion tabs 38 are spaced a distance from the lugs 34. In the illustrated embodiment, the first surface 38a is spaced between approximately 2.3 mm and approximately 2.5 mm from the lugs 34. The electrical terminal 30 has a width W1, measured from the outer surfaces of the insertion tabs 38, of approximately 5.0 mm to approximately 5.2 mm, as shown in Fig. 3 is shown.

[0024] A portion 37 of the tuning fork-like connector socket 30b between the insertion lugs 38 and the lugs 34 has a width W6 of between approximately 3.9 mm and approximately 4.1 mm, as also shown in Fig. 3 is shown.

[0025] The dimensions of the electrical connector 30, including the blade contact portion 30a and the tuning fork-like terminal socket 30b described above, are not limited to the disclosed dimensions and may have any other desired dimensions.

[0026] In Fig. 5, a second embodiment of an electrical terminal is shown at 40. The electrical terminal 40 is substantially similar to the electrical terminal 30 and has the first end 30a, which is designed as a blade contact part, and a second embodiment of the second end 40b.

[0027] The second end 40b is configured as a tuning fork-like connector socket and includes two substantially parallel rods 32 defining the slot 33 formed between them. Connecting projections or elements 32a extend inwardly from the rods 32 (into the slot 33).

[0028] The tuning fork-type terminal socket 40b includes insertion tabs 42 substantially identical to the insertion tabs 38. They have a first surface 42a and a second or tool engagement surface 42b, but extend outwardly from the tuning fork-type terminal socket 40b at the interface of the blade contact portion 30a and the tuning fork-type terminal socket 40b. Thus, the first surfaces 42a of the insertion tabs 42 form the projections 44.

[0029] The electrical terminal 40 has a width W1, measured from the outer surfaces of the insertion tabs 38, of approximately 5.0 mm to approximately 5.2 mm, as shown in Fig. 5 is shown.

[0030] The mounting portion 36 is formed between the blade contact part 30a and the first surface 42a of the insertion lugs 42. As described above, the mounting portion 36 has a width W3 that is greater than the width W2 of the blade contact part 30a.

[0031] The dimensions of the electrical connector 40, including the blade contact portion 30a and the tuning fork-like terminal socket 40b described above, are not limited to the disclosed dimensions and may have any other desired dimensions.

[0032] In Fig. 6, a third embodiment of an electrical terminal is shown at 50. The electrical terminal 50 is substantially similar to the electrical terminal 30 and has a first end configured as a blade contact portion 50a and a third embodiment of the second end 50b. The illustrated blade contact portion 50a has a width W4 of between approximately 1.1 mm and approximately 1.3 mm.

[0033] The third embodiment of the second end 50b is configured as a tuning fork-type connector socket and is substantially similar to the first embodiment of the tuning fork-type connector socket 30b, except that a portion 51 of the tuning fork-type connector socket 50b between the insertion tabs 38 and the lugs 34 has a width W7 of between approximately 2.9 mm and approximately 3.1 mm. The tuning fork-type connector socket 50b includes the two substantially parallel rods 32 defining the slot 33 formed therebetween and the connecting elements 32a, as described in detail above.

[0034] The electrical terminal 50 further includes a mounting portion 52 formed between the blade contact portion 50a and the tuning fork-like terminal socket 50b. The mounting portion 52 has a width W5 that is greater than the width W4 of the blade contact portion 50a. The illustrated mounting portion 52 has a width W5 between approximately 2.2 mm and approximately 2.4 mm and is configured for insertion and mounting into the openings 12c of the PCB 12.

[0035] The insertion tabs 38 extend outwardly from the tuning-fork-like terminal socket 50b between the lugs 34 and the rods 32 and include the first surface 38a and the second, or tool-engaging, surface 38b. In the illustrated embodiment, the first surface 38a is spaced between approximately 2.3 mm and approximately 2.5 mm from the lugs 34. The electrical terminal 50 has a width W1, measured from the outer surfaces of the insertion tabs 38, of approximately 5.0 mm to approximately 5.2 mm.

[0036] The dimensions of the electrical connector 50, including the blade contact portion 50a and the tuning fork-like terminal socket 50b described above, are not limited to the disclosed dimensions and may have any other desired dimensions.

[0037] In Fig. 7, a fourth embodiment of an electrical terminal is shown at 60. The electrical terminal 60 is substantially similar to the electrical terminal 50 and includes the first end configured as a blade contact portion 50a with a width W4, the mounting portion 52 with a width W5, the tuning fork-like terminal socket 40b, and the insertion tabs 42.

[0038] The tuning fork-like connector socket 40b includes two substantially parallel rods 32 defining the slot 33 formed therebetween. Each rod 32 includes the connecting projection or connecting element 32a. The insertion tabs 42 include the first surface 42a and the second or tool engagement surface 42b, with the first surfaces 42a forming the lugs 44.

[0039] In Fig. 8, an advantageous, but not inventive, embodiment of an electrical terminal is shown at 70. The electrical terminal 70 includes a body 71 having a first end 71a and a second end 71b. The first end 71a has a mounting pin 73 extending therefrom and forms the lugs 34 adjacent the mounting pin 73. The body 71 is substantially similar to the second end 30b and includes the two substantially parallel bars 32 defining the slot 33 formed therebetween. Each bar 32 includes the connecting projection or member 32a. The body 71 further includes the insertion lugs 38 extending outwardly from the body 71 between the lugs 34 and the bars 32. The insertion lugs 38 include the first surface 38a and the second or tool engagement surface 38b. The insertion lugs 38 are spaced at a distance from the lugs 34.In the illustrated embodiment, the first surface 38a is spaced between approximately 2.3 mm and approximately 2.5 mm from the lugs 34.

[0040] In Fig. 9, an advantageous, but not inventive, embodiment of an electrical terminal is shown at 80. The electrical terminal 80 comprises a body 81 having a first end 81a and a second end 81b. The first end 81a has a mounting pin 83 extending therefrom. The body 81 is substantially similar to the second end 40b and comprises the two substantially parallel bars 32 defining the slot 33 formed therebetween. Each bar 32 comprises the connecting projection or connecting element 32a. The body 81 further comprises the insertion tabs 42 extending outwardly from the body 81 at the first end 81a thereof and having the first surface 42a and the second or tool engagement surface 42b, the first surface 42a of the insertion tabs 42 forming the lugs 44.

[0041] The dimensions of the electrical terminals 70 and 80, including the components thereof described above, are not limited to the disclosed dimensions and may have any other desired dimensions.

[0042] The illustrated mounting pin 83 has a tapered distal end. It is understood that the terminals 70 and 80 engage the mounting pin 73, as shown in Fig. 8, or the tapered mounting pin 83, as shown in Fig. 9 is shown.

[0043] As described above, the electrical terminals 40, 60, and 80 are substantially similar in that the insertion tabs 42 form the bosses 44. In a substantially similar manner, the electrical terminals 30, 50, and 70 are substantially similar in that the insertion tabs 38 are spaced an equal distance from the bosses 34 and are therefore spaced an equal distance from the second major surface 12b of the PCB 12.

[0044] It will be understood that the insertion tabs 42 on the electrical terminals 40, 60 and the insertion tabs 38 on the electrical terminals 30, 50, and 70 can be formed at any desired axial location so that when incorporated into a PCB unit as shown in Fig. 3 at 90, each insertion tab 38 may be axially spaced from an adjacent insertion tab 42 by a distance D1 for reasons to be described below. In the illustrated embodiment, the distance D1 is approximately 0.5 mm. Alternatively, the distance D1 may be any desired distance, including a distance less than about 0.5 mm and a distance greater than about 0.5 mm.

[0045] In Fig. 2 and Fig. 3, an improved PCB unit according to the invention is shown at 90, which is shown in a first or second step of a method for assembling the improved PCB unit 90 according to the invention.

[0046] As in Fig. 2, an insertion tool 92 includes a body 94 having a recess 94a configured to receive the tuning fork-type terminal receptacle 40b and terminal engagement surfaces 94b. The tool 92 is disposed around the tuning fork-type terminal receptacle 40b of the terminal 40 such that the terminal engagement surfaces 94b engage the tool engagement surfaces 42b of the insertion tabs 42. A force is applied to the tool 92 in the direction of arrow A, forcing the blade contact member 30a into the opening 12c until the lugs 44 engage and seat the second major surface 12b, thereby mounting the terminal 40 to the PCB 12. A solder (not shown) may then be applied to one or both of the first and second major surfaces 12a and 12b on the terminal 40 to effect an electrical connection therebetween.

[0047] In Fig. 2, terminals 60 and 80 are shown assembled in the same manner as terminal 40. Although tool engagement surface 42b of terminal 40 is shown as the second surface of insertion tabs 42, terminals 40, 60, and 80 can be configured such that tool engagement surface 42b is formed on any desired portion of terminals 40, 60, and 80. In substantially the same manner, tool 92 can be configured such that terminal engagement surfaces 94b are formed on any desired portion of tool 92 that engages terminals 40, 60, and 80 and allows terminals 40, 60, and 80 to be forced through openings 12c and into contact with second major surface 12b of PCB 12. Each terminal 60 and 80 may further be mounted to the PCB 12 in the same manner as the terminal 40, with the blade contact part 50a or the mounting pin 83 being pressed into an opening 12c of the PCB 12.

[0048] As in Fig. 3, the insertion tool 92 is disposed around the tuning-fork-like terminal socket 30b of the terminal 30 such that the terminal engagement surfaces 94b engage the tool engagement surfaces 38b of the insertion tabs 38. A force is applied to the tool 92 in the direction of arrow B, forcing the blade contact portion 30a into the opening 12c until the lugs 34 engage and seat the second major surface 12b. A solder (not shown) may then be applied to the terminal 30 on one or both of the first and second major surfaces 12a and 12b to effect an electrical connection therebetween.

[0049] Each terminal 50 and 70 can also be mounted on the PCB 12 in the same manner as the terminal 30, wherein the blade contact part 50a or the mounting pin 73 is pressed into an opening 12c of the PCB 12. In Fig. 3 shows the terminals 50 and 70 after assembly in the same way as for terminal 30.

[0050] How to continue in Fig. 3, when mounted on the PCB 12, the insertion tabs 42 of the terminals 40, 60, and 80 are coplanar and linearly aligned along a line L2. In substantially the same manner, when mounted on the PCB 12, the insertion tabs 38 of the terminals 30, 50, and 70 are coplanar and linearly aligned along a line L3. In the illustrated embodiment, the terminals are mounted such that each of the terminals 30, 50, and 70 is mounted alternately with each of the terminals 40, 60, and 80. This arrangement ensures that a terminal having the insertion tabs 38 is adjacent to a terminal having the insertion tabs 42.

[0051] As in Fig. 3, the insertion tabs 42 of terminals 40, 60, and 80 and the insertion tabs 38 of terminals 30, 50, and 70 are axially spaced apart by the distance D1. This axial spacing allows adjacent terminals to be mounted closer together than is possible with known PCB units, such as the one shown in Fig. 1 shown PCB unit 10. Accordingly, a minimum center-to-center distance CL2 between two adjacent terminals, as shown in Fig. 3, be smaller than the center-to-center distance between terminals in known PCB units, such as the one shown in Fig. 1 shown PCB unit 10. For example, the PCB unit shown in Fig. 3, the center-to-center distance CL2 is between approximately 5.0 mm and approximately 5.2 mm. Alternatively, the center-to-center distance CL2 may be any desired distance, including a distance less than approximately 5.0 mm and a distance greater than approximately 5.2 mm.

[0052] In the illustrated embodiment, the adjacent terminals are spaced apart transversely such that an outer surface 38c (a typical example of such is shown in the terminal 70 in Fig. 3) of the insertion lugs 38 by a distance D2 from an outer surface 42c (a characteristic example of such is shown in the terminal 80 in Fig. 3) of the insertion tabs 42. In the illustrated embodiment, the distance D2 is approximately 0.5 mm. Alternatively, the distance D2 may be any desired distance, including a distance of less than approximately 0.5 mm and a distance of greater than approximately 0.5 mm.

[0053] As with a known PCB assembly, the electrically conductive terminals of the improved PCB assembly 90 may not touch each other. It should be understood that any two terminals (30, 40, 50, 60, 70, and 80) of the improved PCB assembly 90 may be arranged in any position relative to each other so that they do not touch each other.

[0054] For example, adjacent terminals may be mounted so that their respective insertion tabs 38 and 42 are positioned in an overlapping arrangement, but they may be spaced apart by a distance such that they do not touch each other.

[0055] Furthermore, during assembly of the illustrated improved PCB assembly 90, the space provided by the distance D2 between the outer surfaces 38c and the outer surfaces 42c allows the insertion of the tool 92 into the space between adjacent terminals. The distance D2 between adjacent terminals further provides the advantage of providing space for a portion of a non-conductive member, such as a wall of a connector body or a junction box body, to be disposed and secured therein between the adjacent terminals. It should be understood, however, that the distance D2 need not be large enough to allow the insertion of the tool 92 or a portion of the non-conductive member.

[0056] The Fig. The exemplary embodiments of the electrical terminals 30, 40, 50, 60, 70, and 80 illustrated in Figures 4 through 9 include first ends configured as blade contact portions and second ends configured as tuning-fork-type female terminals. It should be understood that the first ends of the electrical terminals 30, 40, 50, 60, 70, and 80 may have any design, configuration, or shape suitable for use with a PCB. In substantially the same manner, the second ends of the electrical terminals 30, 40, 50, 60, 70, and 80 may have any design, configuration, or shape suitable for use with a PCB and require one or more insertion tabs thereon.

[0057] Furthermore, each of the Fig.4 to 9, the exemplary embodiments of the electrical terminals 30, 40, 50, 60, 70, and 80 have two insertion tabs formed thereon. It should be understood that the electrical terminals 30, 40, 50, 60, 70, and 80 may have any desired number of insertion tabs formed thereon, including only one insertion tab formed thereon.

[0058] The principle and mode of operation of the invention have been described in its preferred embodiments. However, it should be understood that the invention described herein may be practiced otherwise than as specifically shown and described without departing from the scope thereof.

Claims

[1] Printed circuit board (PCB) unit (90), comprising: a PCB (12) having a first surface (12a) and a second surface (12b); a first electrical terminal (30, 50) mounted on the PCB (12), the first electrical terminal (30, 50) comprising a body having a first end (30a, 50a) and a second end (30b, 50b), a mounting portion (36, 52) extending outwardly from the first end (30a, 50a) and adapted to be inserted into an opening (12c) formed in the PCB (12), lugs (34) formed adjacent to the mounting portion (36, 52) and a first insertion tab (38) extending outwardly from the body at the first end (30a, 50a) thereof, wherein the lugs (34) of the first electrical terminal (30, 50) are disposed between the first insertion tab (38) and the mounting portion (36, 52) of the first electrical terminal (30, 50); and wherein the lugs (34) of the first electrical terminal (30, 50) are configured to engage the second surface (12b) of the PCB (12); and a second electrical terminal (40,60) mounted adjacent to the first electrical terminal (30,50) on the PCB (12), the second electrical terminal (40,60) having a body with a first end (30a,50a) and a second end (40b), a mounting portion (36, 52) extending outwardly from the first end (30a, 50a) and adapted to be inserted into an opening (12c) formed in the PCB (12), lugs (44) formed adjacent to the mounting portion (36, 52), and a second insertion tab (42) extending outwardly from the body at the first end (30a, 50a) thereof, the lugs (44) of the second electrical terminal (40, 60) being disposed on a first surface (42a) of the second insertion tab (42) and being adapted to engage the second surface (12b) of the PCB (12); wherein the first insertion lug (38) and the second insertion lug (42) are axially spaced from each other so that the first electrical terminal (30, 50) and the second electrical terminal (40, 60) do not touch each other. [2] The PCB assembly (90) of claim 1, wherein the first insertion tab (38) extends outwardly from the body between the lugs (34) and the second end (30b,50b). [3] The PCB unit (90) of claim 1, wherein the first surface (42a) of the second insertion tab (42) forms one of the lugs (44). [4] The PCB assembly (90) of claim 1, wherein the first insertion tab (38) of the first electrical terminal (30, 50) is linearly aligned along a first line (L3), the second insertion tab (42) of the second electrical terminal (40, 60) is linearly aligned along a second line (L2), and the first and second insertion tabs (38, 42) are coplanar. [5] The PCB unit (90) of claim 1, wherein one of the first and second electrical terminals (30,50; 40,60) has two insertion tabs. [6] The PCB unit (90) of claim 1, wherein the first and second electrical terminals (30,50; 40,60) are positioned in an overlapping arrangement. [7] The PCB assembly (90) of claim 1, wherein each of the first and second electrical terminals (30, 50; 40, 60) has a tool engagement surface (38b; 42b) formed thereon, the tool engagement surface (38b; 42b) being configured to engage an insertion tool (92). [8] The PCB unit (90) of claim 7, wherein the tool engagement surface (38b; 42b) on each of the first and second electrical terminals (30, 50; 40, 60) is formed on a surface of the first and second insertion tabs (38, 42). [9] A method of manufacturing a printed circuit board (PCB) unit (90), comprising the steps of: Mounting a first electrical terminal (30, 50) in an opening (12c) formed in a PCB (12), the PCB (12) having a first surface (12a) and a second surface (12b); and Mounting a second electrical terminal (40,60) adjacent to the first terminal (30,50) in an opening (12c) formed in the PCB (12); wherein the first electrical terminal (30, 50) comprises a body having a first end (30a, 50a) and a second end (30b, 50b), a mounting portion (36, 52) extending outwardly from the first end (30a, 50a) and adapted to be inserted into the opening (12c) formed in the PCB (12), Lugs (34) formed adjacent to the mounting portion (36,52), and a first insertion tab (38) extending outwardly from the body at the first end (30a, 50a) thereof, wherein the lugs (34) of the first electrical terminal (30, 50) are disposed between the first insertion tab (38) and the mounting portion (36, 52) of the first electrical terminal (30, 50); and wherein the lugs (34) of the first electrical terminal (30, 50) are configured to engage the second surface (12b) of the PCB (12); wherein the second electrical terminal (40,60) comprises a body having a first end (30a,50a) and a second end (40b), a mounting portion (36,52), which extends outwardly from the first end (30a, 50a) and is adapted to be inserted into the opening (12c) formed in the PCB (12), includes lugs (44) formed adjacent to the mounting portion (36, 52) and a second insertion tab (42) extending outwardly from the body at the first end (30a, 50a) thereof, the lugs (44) of the second electrical terminal (40, 60) being disposed on a first surface (42a) of the second insertion tab (42) and being adapted to engage the second surface (12b) of the PCB (12); wherein the first insertion lugs (38) and the second insertion lugs (42) are axially spaced from one another so that the first electrical terminal (30, 50) and the second electrical terminal (40, 60) do not touch one another.

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